a case study of manufacturing automation in automotive ... · pdf fileof manufacturing...

12th April '07, Mumbai 1

A Case Study of

Manufacturing Automation in

Automotive Industry

L P PEREIRA

Sr. Vice PresidentMahindra & Mahindra Ltd


Automobile Manufacturing Areas

Pressing,Foundry, Forging

Body Shop &

Welding

Pre-treatment &

Painting

Vehicle Assembly& Testing

Machining

Assembly &

TestingDriveline


1. Enhanced Operational Safety

2. Complexity of Operation

3. Large Volumes & Low TACT Time

4. Minimising Variability in Output Quality

5. Defect Prevention

6. Enhancing Utilisation of Assets to

meet Peak Demands

8. Lowering the Cost of Manufacture

9. Integration of Operational Processes

Key Drivers For Automation


Level of Automation

A detailed analysis is necessary in terms of

feasibility, techno-economics, viability, sensitivity

& reliability to decide the level and mode of

Automation.

Automation is a high levered tool in de-

bottlenecking an operation in an un-balanced line.


• Fixed AutomationEntails high investments for custom

engineered equipment used for high production volumes.

• Programmable AutomationMost suitable for batch production with

flexibility to do variety of jobs.

• Flexible AutomationRequires high investments to meet

continuous production of variety of jobs with medium production volumes.

Types of Automation


Areas of Automation

Body Shop / Welding

Automation in body shop/ welding provides

for a very high productivity, flexibility, consistency in

quality, access in difficult areas and a relief from

fatigue & health hazards.


Areas of Automation

Paint shop

Robotic/Programmable painting increases

productivity of plants multifold, conserving resources

of capital, paints & chemicals, & relief from health

hazards.

Quality & consistency of painting through

automated Paint shops & Paint mixing, is much better

with respect to manual operation.


Areas of Automation

Machining

Use of CNC machines, FMC, FMS, CIM

enhances substantially, not only productivity &

precision, but also flexibility.

Components can be finished & supplied on line,

starting from raw materials without human

intervention especially when volumes are high.


Areas of Automation

Assembly Operations

Automation is generally for Mistake proofing,

reduced variability and system discipline.

Also at large volumes and very low TACT times,

manual operations are not feasible, at times.


Areas of Automation

Demand Management & Logistics

Digital Automation & use of ERP systems for

seamless & effective integration of Operations

internally and with the supplier base supporting

SCM, RFID, JIT and DOL for meeting customer

commitments in the most cost effective manner.


Case Study of Automation

at Mahindra & Mahindra


Features Manual Painting Robotic PaintingQuality Consistancy of Paint Application

Varies with person to person and over a shift

Consistant

Paint Consumption 30% Utilised and 70% Wastage

75% Utilised and 25% Wastage

Reach in Intricate areas Limited Reach Flexible

Painting Speed Limited Fairly High

Manual v/s Robotic Painting


Process Integration with SCADA

What is SCADA?

• Supervisory

• Control

• And

• Data

• Acquisition


SCADA• The SCADA is designed to have

supervisory control from centralized

location .It forms a single point source of

data of a plant to be controlled.

• It is being used in Scorpio B/S, Scorpio

TCF, New Paint Shop, Power & Free & MQS

Paint shop.


• At a glance body tracking. No need of physical tracking &

counting of Body Shells.

• Maintenance trouble shooting of system equipment

Quick Identification by alarm displays & “ MTTR ” (Mean

Time to Repair) reduction.

Benefits of SCADA


SCADAMAIN SCREEN


SCADA


Engine Manufacturing

PISTON RINGAutomatic Side Detection & Stacking


Piston Ring Side DetectionAutomation Necessity

• Position of top side marking is very essential during

Piston Ring assembly for desired Engine Performance.

• Need to check @ 400 Rings / hour for marking on

up-side & insertion on piston.

• Development of an low cost Automated System to

inspect off line & stack for assembly improved quality &

productivity.


Piston Ring Checking Automation

• Optical Sensor

Light Emitter

RECEIVER


Piston Ring Automation

OK

REV

Not OK Check & separate

STACK RECEIVED

• Auto system


Piston Ring


• Automation plays a significant role in our

effort to satisfy the customer demands of

newer models which are reliable, safe and

defect free at competitive prices.

To Sum-up


Thank You

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